AFFINITY™ F-SERIES CHILLER
Contents
1. recharge to specifications on serial tag Problem Chiller shuts down during operation continued Temperature display reads incorrectly Too much recirculating pressure to process Compressor turns on and off automatically Chiller cools well below desired Setpoint Compressor does not run Possible Cause Pump overload setting too low Pump overload tripped Low voltage Loose wire Broken RTD Microprocessor failure Flow control valve set too high Pressure relief valve set too high unless not adjustable Discharge pressure too high Condenser fan s not on Refrigeration high pressure cut out set to automatic Microprocessor programmed incorrectly Malfunctioning solenoid valve Solid State Relay failure Microprocessor failure Compressor internal thermostat tripped Motor burned out Possible Remedy Adjust and reset pump thermal overload relay to specifications or replace if faulty Determine reason for trip If pump is damaged repair or replace Check service to chiller Check wiring after disconnecting power Replace RTD Replace microprocessor Throttle flow control valve Adjust pressure relief valve Determine cause and correct Check motor s and wiring Check settings Reprogram microprocessor Call Lydall Repair or replace solenoid valve Replace Solid State Relay Replace microprocessor Allow time for compressor to cool and automatically reset R2. shock and vibration or the warranty will be void The chiller must not be transported unless suitably protected Original factory packaging in good condition or equivalent is required Request air ride trucks when transporting over land Before shipping or storing the unit it must be thoroughly drained and blown dry with low pressure air Lydall will not accept any unit containing measurable amounts of fluid Fluid left in the unit during shipping may damage components within the unit Such damage is not covered by warranty Placement Select a level location near the application free from dripping or spraying moisture and excessive dust Keep the coolant lines short to allow the pump to provide maximum pressure and flow to the application If the chiller will be placed more than 25 feet from the application call Lydall to discuss placement and how it might affect performance Units with non pressurized reservoirs should never be installed more than 25 feet below the process or overflow may occur Distances may vary slightly due to elevations above sea level Call Lydall service for more information Electrical Requirements Connect the chiller to a properly fused disconnect box in compliance with the NEC National Electric Code as well as state and local codes for American usage or national and local codes for European usage Maximum fuse sizes in the disconnect box must not exceed the maximum ratings specified on the serial tag of the chil
3. AFFINITY F SERIES CHILLER User Manual D5075 Lydall Industrial Thermal Solutions Inc Post Office Box 1000 775 Route 16 Ossipee NH 03864 USA Telephone 603 539 3600 Sales 603 539 5005 Service Fax 603 539 8484 O MANUALS D5076 REV E 05 23 2002 NMT Table of Contents Introduction Equipment Precautions Safety Precautions Installation Transporting Placement Electrical Requirements Priming the Pump and Connecting the Coolant Loop Operation Using the Controller Changing the Set Value Temperature Safety Alarms Communications Preventive Maintenance Trouble Shooting Guide Warranty Refrigeration Diagram Fluid Flow Diagram Electrical Schematic OA MANUALS D3877 11 12 2002 Introduction Lydall Affinity Congratulations on your purchase of an Affinity product want to personally welcome you to the Lydall larger family In October of 2001 Lydall purchased Affinity Industries in an effort to expand capability as a Total Thermal Solutions Provider Affinity s chillers and heat exchangers complement Lydall s existing wide array of Passive Thermal Solutions augmenting Lydall s engineered thermal solutions for use in appliance cryogenic building products and automotive markets Our group is market driven as a formidable thermal solution manufacturer Lydall Inc is a New York Stock Exchange listed company NYSE LDL headquartered in Manchester CT Our company with ten operations in the United Stat
4. chiller without express written consent from Lydall will void the warranty OAMANUALS D3792 10 22 2002 Safety Precautions 1 2 Ta Heed all warning labels Do not remove Do not operate the chiller with the bonnet removed The bonnet protects personnel from rotating parts and hot surfaces and also protects the chillers components Connect the chiller to a properly fused disconnect box in compliance with the NEC National Electric Code as well as state and local codes for American usage or local and national codes for European usage Maximum fuses must not exceed the maximum rating found on the serial tag on the electrical box The voltage phase and frequency of the power source must also match the requirements specified on the serial tag To reduce the risk of electric shock Do not remove cover of the remote control box if included Refer servicing to properly qualified and licensed personnel Disconnect electrical power before opening the electrical box except for the checking of the phase reverse relay or phase monitor if included with this unit phase reverse relays or phase monitors will never be included in single phase units Power must be applied in order for the phase reverse relay or phase monitor to indicate phase sequence Do not operate equipment with damaged electric power cords Turn off the chiller and disconnect electric power before servicing or moving Coolant lines filters and other components wh
5. eplace Call Lydall Problem Microprocessor does not work OAMANUALS D3631 05 17 2002 Possible Cause 5 second delay has not timed out Microprocessor programmed incorrectly Microprocessor failure Possible Remedy Wait at least 5 seconds after turning on Reprogram microprocessor Call Lydall Replace microprocessor Warranty The Lydall Limited Warranty Twelve Month Warranty Parts and Labor Lydall Industrial Thermal Solutions Inc warrants this product to the original Owner for a period of twelve 12 months from the date of shipment Lydall will repair or at its discretion replace any part found to contain a manufacturing defect in material or workmanship without charge to the Owner for twelve months from date of shipment Shipping costs are excluded from warranty Service labor will be at no charge during the warranty period as long as the labor is supplied at the Lydall plant in Ossipee New Hampshire or by a Lydall approved service provider Replacement or repaired parts will be warranted only for the un expired portion of the original Warranty To obtain prompt warranty service contact Lydall PO Box 1000 Ossipee New Hampshire 03864 USA Before returning any equipment to Lydall for repair it is necessary to contact the Lydall Service Department for a Return Material Authorization number and an authorized service depot location where the repairs will be completed This Warranty does not cover
6. es France one in Germany and Sales Service Offices in Japan and Singapore is recognized for working with customers to satisfy their unique thermal solution needs and for delivering high quality innovative products and exceptional service Affinity products are high precision specialty temperature controlled equipment The following product manual is designed to help you realize the full value of your purchase We highly recommend that you read this manual in its entirety The manual will assist your company with the installation operation and routine maintenance of your Affinity product Please keep this manual readily accessible to operation and service personnel to ensure you get the most out of our product If you have any questions about this model or have other thermal solution needs do not hesitate to call our Sales department 603 539 3600 or the 24 7 Service department 603 539 5005 Thank you for your confidence in our ability to meet and or exceed your needs and expectations Sincerely John Tattersall Group Vice President Lydall Industrial Thermal Solutions Inc OA MANUALS D3774 01 11 2002 Equipment Precautions Failure to adhere to these precautions will void the warranty and may damage the chiller 1 The chiller has been shipped without coolant Do not run the chiller without connecting the coolant lines and keeping them filled with the appropriate coolant Never run the pump without prime because it
7. from the chiller to the RS232 converter on pins 2 3 and 5 This unit contains advanced communications diagnostics Diagnostics displays include all alarms and faults as well as integrated temperature control For additional information on the WinChill communications interface consult the WinChill manual also supplied with this unit In order for units with WinChill RS232 Communications to meet CE Compliance the external RS232 cable which connects the unit to the customer s equipment must be shielded This is required to meet the EMC immunity requirements of EN61326 for industrial locations The cable must not exceed 30 feet in length The shield construction must be a braid minimum 85 tinned copper over aluminum foil minimum 100 coverage shield with a 360E shield termination at each end of the cable One possible source for cable meeting this requirement is Black Box part number EGM12D For units with WinChill RS485 communications the cable must not exceed one thousand feet in length Operation Preventive Maintenance A stainless steel mesh strainer attaches to the pump suction port near the bottom of the reservoir It can easily be removed for cleaning First turn the pump off then pull off the strainer rinse it clean and push it back on To protect the pump routinely inspect the strainer to be sure it is clean and properly attached Hint If the strainer is coated with debris wrap it with a plastic sandwich bag before pullin
8. g it off to prevent most of the debris from escaping into the reservoir The frequency of checking and cleaning this strainer will depend on the cleanliness of the process and the fluid Regularly check the condenser located in front of the fan for dirt dust etc To clean disconnect the electrical power cord and remove the bonnet Check and clean the condenser as required using a vacuum or low pressure air Condenser fins bend easily Use care when cleaning O A MANUALS D3879 05 17 2002 Problem Unit does not start Unit does not cool Trouble Shooting Guide Possible Cause No power to unit breaker tripped Low voltage Refrigeration high pressure cut out tripped Loose wire Defective contactor or coil Loss of refrigerant Compressor damaged Compressor internal thermostat tripped Compressor damaged Room temperature exceeds 85EF causing cooling capacity of unit to be derated Evaporator damaged Microprocessor programmed incorrectly Cooling load exceeds capacity of unit Microprocessor failure Loss of refrigerant Refrigeration solenoid coil failure Possible Remedy Verify power to unit close breaker after correcting fault Check electrical service to unit Will automatically reset after correcting fault Check wiring after disconnecting power Repair or replace contactor or coil Repair leak then recharge with type and amount of refrigerant specified on serial tag Replace com
9. ich connect to the chiller must be capable of withstanding the maximum pressure that the pump in the chiller can deliver at the maximum expected temperature The coolant loop has not been designed for potable water applications Do not use the chiller for potable water Never hook the water lines of a water cooled unit to a potable water source or immerse a hose connected to a potable water source in the reservoir without providing back flow protection A loss of pressure in the water source could lead to a back flow of the fluid in the unit resulting in a possible contamination of the potable water source Vapors of some alcohol based antifreezes as well as other coolants may cause explosion if exposed to flame or spark Certain antifreezes may be poisonous if ingested OAMANUALS D3799 10 03 2002 Installation Transporting An Affinity chiller rolls easily on its four swivel casters The brakes must be off on the two locking casters when moving the chiller Roll the chiller gently to its operating location The cushioned casters will help to dampen shock Lock the casters when the unit is in place If the chiller will be carried with a lift truck proceed slowly and carefully to avoid jarring the chiller Insert the forks from the condenser or electrical box side the longer dimension to catch both of the reinforcing rails of the chassis taking care to prevent damage to the casters If the chiller will be shipped protect it from
10. inue filling the reservoir until the low level alarm shuts off Do not allow the reservoir to overflow 8 If the pump does not establish prime disconnect the SUPPLY coolant line to vent any trapped air reconnect the line and repeat step 7 9 If the pump still does not prime use the following steps a Disconnect both coolant lines have a container handy to catch any overflow from the RETURN fitting b Force coolant into the SUPPLY fitting The fluid will force the air out of the lines in the chiller and out of the pump head causing it to escape into the reservoir If tap water will be the source of coolant simply connect the tap water line to the SUPPLY fitting and turn on the tap If a source of coolant other than tap water will be used elevate the coolant a few feet above the chiller connect to the SUPPLY fitting and let gravity force the air out into the reservoir Remember to have a container handy to catch any overflow from the RETURN fitting C Reconnect the coolant lines and repeat step 6 Stop filling when the reservoir is full to within a few inches of the top Do not allow the reservoir to overflow OAMANUALS D10084 05 22 2002 Operation Using the Controller This chiller comes with a FUJI ELECTRIC 1 16 DIN temperature controller This controller is a programmable microprocessor which offers many more features than are necessary to master at this point This controller come pre programmed according to the Affini
11. lean and reinstall or replace Reverse one electrical phase Open flow control valve Adjust pressure relief to specification Check for leaks then fill reservoir Problem Low coolant flow continued No coolant flow Chiller shuts down during operation Possible Cause Restriction in coolant lines external to chiller Frozen evaporator Flow switch clogged Pump not primed Pump suction strainer clogged No coolant in reservoir Pump overload tripped Pump motor shaft bound to seal Pump housing improperly torqued Damaged pump Frozen evaporator Clogged line or closed valve in external piping Leak s in external piping Refrigeration high pressure cut out set too low Refrigeration low pressure cut out set too high Dirty condenser fins Excess refrigerant charge Possible Remedy Eliminate restrictions in coolant lines external to chiller Call Lydall Disassemble flow switch clean and reinstall or replace Prime pump Remove and clean strainer then reinstall Check for leaks then fill reservoir Wait 5 minutes for overload to reset Replace pump or renew seal Remove pump torque to specifications test and reinstall Replace pump Call Lydall Check external piping for dirt or closed valve Check for leaks and repair if needed Adjust and reset high pressure cut out Adjust and reset low pressure cut out Gently clean condenser fins Remove excess refrigerant and
12. ler found on the electrical box near where the power cord connects The voltage phase and frequency of the power source must also match the requirements specified on the serial tag Note Affinity models that can operate at 208 230 Volts 60 Hertz have been set at the factory for 208 220 Volt operation If the operating voltage will be greater than 220 Volts a qualified electrician should remove the red wire from the contactor and replace it with the orange wire taken from the dummy fuse block Attach the red wire to the dummy fuse block as shown in the diagram below Installation ELECTRICAL SCHEMATIC CONNECT FOR SYSTEM VOLTAGE PRIMARY CONNECTIONS as NOT USED MUST BE ISOLATED AND CAPPED REMOVED FROM POWER TERMINAL NOTE IN SOME CASES PRESSURE SCREW TERMINAL BLOCKS ARE USED IN PLACE OF FASTON TERMINATIONS Warning To reduce the risk of electric shock do NOT remove cover from the electrical box It contains exposed high voltage wires Refer servicing to qualified personnel Disconnect power to the chiller before servicing Priming the Pump and Connecting the Coolant Loop DO NOT RUN THE PUMP DRY If the pump does not establish prime the pump shaft seal may overheat and be damaged in less than a minute Use the following instructions when filling and assembling the coolant lines to prevent damage to the pump shaft seal 1 Close the reservoir drain 2 Fully open the flow control valve if included 3 Have e
13. ll Lydall Check electrical service Connect to proper taps Replace contactor or coil Reset pump thermal overload relay or replace if faulty Correct voltage Warm crankcase if unit has been off for a long period or has been left in a cool ambient for more than a few hours Problem Noisy compressor continued Level light remains on Level light does not work Fault light remains on Low coolant flow Possible Cause Worn compressor Refrigeration high pressure cut out set too high Refrigeration low pressure cut out set too low Low coolant level Reservoir level switch float stuck Time delay relay malfunction when used Level switch failure Time delay relay has not timed out when used Lamp burned out Level switch failure Low coolant flow No coolant flow Flow switch sticking Pump suction strainer clogged Pump rotating backwards Flow control valve not fully open Pressure relief valve set too low unless not adjustable Low coolant level in reservoir Possible Remedy Replace compressor Call Lydall Adjust setting Adjust setting Check for leaks then fill reservoir Clean reservoir and level switch Replace time delay relay Replace level switch Wait for time delay relay to time out Replace lamp Replace level switch See Problem Low coolant flow See Problem No coolant flow Disassemble flow switch clean and reinstall or replace Remove strainer c
14. o operate at higher coolant temperatures Never program in a Set Value temperature of less than 5EC 40EF unless a suitable antifreeze is used as coolant AND this unit is designed to operate at below freezing temperatures Turn the whole system on by placing the ON OFF SET switch in the ON position The Set Value temperature can be changed with the switch in either the ON or SET position Air bubbles will be visible rising in the reservoir as the pump forces air out of the coolant loop After the air has been purged from the coolant loop a steady turbulence will appear in the reservoir This turoulence mixes the coolant to deliver more precise temperature stability in the coolant supply than the controller indicates Safety Alarms Temperature The controller has ALM1 and ALM2 lights ALM2 may or may not operate depending on the exact model of the PYX controller The alarm s have been preset at the factory to come on when the temperature of the circulating coolant is above or below the temperature the chiller has been set to deliver The OUT1 light on the controller when lit indicates that the refrigerant solenoid valve is open to allow refrigerant to flow to the heat exchanger If the light is on most of the time most of the chiller s capacity is being used If the light is on infrequently much less than the chiller s full capacity is being used Communications The 9 pin connector on the control panel provides RS485 communications
15. pressor Call Lydall Allow time for compressor to cool and automatically reset Replace compressor Call Lydall Improve ventilation air conditioning to maintain room temperature lt 85EF Call Lydall Reprogram microprocessor Call Lydall Reduce cooling load Replace microprocessor Locate and repair leak then recharge with type and amount of refrigerant specified on serial tag Replace solenoid coil Problem Unit does not cool continued Pump leaks Excessive noise on Start Up Pump motor overheats Noisy compressor Possible Cause Solid State Relay failure Solenoid valve stuck shut Defective refrigeration low pressure cut out Malfunctioning thermal expansion valve Pump damaged loss of flow Hot gas bypass valve setting too high Hot gas bypass valve stuck open Dirty condenser fins Faulty pump casing Shaft seal damaged Pump housing O Ring damaged Improper fluid Low voltage Wrong voltage taps used on transformer Contactor or coil failure Pump thermal overload protection set too high Improper voltage supplied Flooding of refrigerant into crankcase Possible Remedy Replace Solid State Relay Repair or replace solenoid valve Repair or replace low pressure cut out Replace thermal expansion valve Replace pump Call Lydall Repair or replace valve Gently clean condenser fins Replace pump assembly Replace shaft seal Remove pump and rebuild Ca
16. s chiller is powered by three phase electricity Verify pump rotation before operating Rotation should be in the same direction as the arrow on the pump casing Only qualified electrical service technicians should switch legs on three phase power to change pump rotation Note Jog the pump very briefly to observe the rotation Verify pump rotation when the chiller is connected to a different circuit 8 Routinely inspect the pump inlet strainer located in the reservoir for debris Turn off the chiller then remove and clean the strainer as required to permit free flow of coolant Prevent foreign debris from entering the coolant line while the strainer is removed Hint Wrap the strainer in a plastic sandwich bag to contain most of the debris Failure to keep the strainer clean will reduce coolant flow and may damage the pump Equipment Precautions 9 10 11 12 13 14 Do not operate the chiller at coolant temperatures above or below the values it was specified to deliver Do not run the chiller with cooling loads that exceed its factory rated cooling capacity Never operate damaged or leaking equipment The chiller must not be transported unless suitably protected Original factory packaging in good condition or equivalent is required Request air ride trucks when transporting over land The chiller must be thoroughly drained and the coolant lines blown dry with low pressure air before shipping or storing Modifying the
17. the following Damage or failure of any part caused by accident customer shipping storage misuse customer modification fire flood Acts of God or resulting from failure to properly install operate or maintain the product in accordance with the printed instructions provided in the User Manual As noted in the User Manual any modification of the unit without expressed written consent from Lydall will void the warranty In no event shall Lydall be liable for any repairs or service or any consequence of any repair or service that are not performed in strict accordance with all applicable city county state and federal laws Further limitations and exclusions This Warranty is in lieu of any other warranties expressed or implied including merchantability or fitness for a particular purpose In no event shall Lydall be liable for any consequential or incidental damages that the Owner may incur resulting from purchase or use of this Lydall product The buyer s sole and exclusive remedy and the liability limit of Lydall for any loss whatever shall not exceed the purchase price paid by the purchaser for the Lydall product on which a claim is made Lydall Industrial Thermal Solutions Inc Post Office Box 1000 775 Route 16 Ossipee NH 03864 USA Telephone 603 539 3600 Sales 603 539 5005 Service Fax 603 539 8484 O AMANUALS D3777 05 06 2002
18. ty model selected If some of the controller s additional features become necessary call Lydall service 603 539 5005 for technical assistance or consult the FUJI ELECTRIC Instruction Manual To power the controller without powering the chiller place the ON OFF SET switch in the SET position The digital display will light up The number next to PV is the actual process coolant temperature The number next to SV is the Set Value desired temperature Lights next to OUT1 OUT2 ALM1 and ALM2 may also appear A light on next to OUT1 when the switch is in the ON position indicates that the chiller is cooling Both ALM1 and ALM2 are alarms that are configured differently for different chillers Changing the Set Value Temperature Change the Set Value by pressing the gt key on the controller keypad SV will change to a leading zero display Continue pressing the gt key until the appropriate digit flashes Press the v or W key on the controller keypad until the digit changes to the desired value Toggle through using the gt v and w keys to change the appropriate digits until the Set Value reads as desired Continue pressing the gt key until the last digit flashes Press the gt key one more time and all leading zeroes will extinguish This locks in the Set Value temperature Operation Caution Never program in a Set Value temperature of more than 32EC 90EF unless this Affinity model is specifically modified t
19. will be quickly damaged without liquid 2 Never use coolants which are incompatible with the components in this chillers coolant loop Some coolants may not damage the coolant loop components yet may significantly derate the chiller s cooling capacity Never use automotive antifreeze or other antifreeze containing silicates because silicates will cause the pump seals to fail Check with Lydall if there are questions about the coolant 3 Maximum storage temperature for the unit is 52EC 125EF 4 This chiller is designed for indoor use only Do not operate the chiller in ambient temperatures below 7EC 45EF or above 30EC 86EF If the chiller has been exposed to temperatures below 7EC allow 24 hours at ambient temperatures above 7EC to warm the oil in the compressor as well as the refrigerant before starting 5 The cabinet of the chiller is designed to vent air Maintain free space equal to the height of the chiller for air flow on the condenser side the side where the coolant lines connect Either the opposite side or the top of the chiller must have an equal amount of free space When air flow becomes impeded cooling capacity decreases and electrical efficiency drops as motor load increases 6 Regularly check the condenser for dirt dust etc Disconnect electric power to the chiller remove the bonnet and clean as required to maintain flow through the condenser Condenser fins are easily bent Use care when cleaning 7 Thi
20. xtra coolant to add as the pump primes and the coolant loop fills 4 Fill the reservoir with coolant Do not fill above the height of the coolant loop connection fittings or fluid may leak out Installation 5 Connect the coolant lines from the application to the FPT female pipe thread fittings near the top of the chiller as follows Do not over tighten the insert and do not use a sealant that will lock the male threads to the female threads a Connect the coolant line coming back from the application to the RETURN fitting b Connect the coolant line going to the application to the SUPPLY fitting J T RETURN SUPPLY 6 Check for proper pump rotation by bump starting the chiller Bump start by placing the ON OFF SET switch in the ON position for one or two seconds Pump rotation should be in the same direction as the arrow on the pump If the direction of rotation is incorrect a qualified electrical technician should exchange any two of the wires in the incoming power source DO NOT change any wiring inside the chiller Check again for proper pump rotation as above 7 When the previous steps are complete turn the chiller on by placing the ON OFF SET switch in the ON position Immediately check for flow If within five seconds no turbulence is visible in the reservoir or the supply pressure gauge shows no pressure reading shut the chiller off by placing the ON OFF SET switch in the OFF position If flow is established cont
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